DE2720616A1 - LAMINATE AND METHOD OF ITS MANUFACTURING - Google Patents

Description

WUPPERTAL 2 PATENT LAWYERS

STRESEMANNSTR. 6-8 DIPl.-ING. H. SONNET

P.O. Box 201327 H. DIPL-ING. H. OSTRIGA

2720616 DIPL.-ING. B. SONNET

Laminate and process for its manufacture

The invention relates to a laminate and a method for its production.

Laminates made from a wide variety of synthetic resins, including polystyrene and foamed polystyrene, are known. It is also known to produce laminates by applying textiles, paper and the like, woven and non-woven materials, to the surface of synthetic resins using an adhesive.

However, all of the laminates known to date have certain disadvantages. For example, they require a separate work process for gluing the surface layer onto the foamed layer, in which case it is sometimes necessary to work with solvents, their recovery or

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Removal can lead to numerous problems, or the surface of the foamed layer to a degree must be heated sufficient to cause melting or sticking of the same what is foamed Layer can adversely affect or even damage, On the other hand, it is known to the surface layer before Heat the coating to a temperature higher than that required to melt the substrate. Thermal damage to the surface layer and / or the foamed layer can also occur here. Furthermore, the known thermal stratification process requires the use of expensive additional equipment.

Another known method is a laminate of foamed and solid polystyrene by direct Melt extruding a sheet of all polystyrene onto a sheet of foamed polystyrene using a kit Chrome-plated rollers made as a carrier and pressing point for the two tracks.

In the above-mentioned known methods, a double layer of material, i.e. a surface layer, is created and a substrate layer to which a third layer can be added by repeating the laminate is passed through the coating level. In other words, for applying the third layer there is a additional work step required.

The invention is accordingly based on the object, on the one hand, of a layer having three or more layers

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Laminate and on the other hand to provide a method for the production of this laminate, in which the aforementioned Disadvantages do not occur.

As far as the objective part of this task is concerned, its solution is characterized by Invention in that the laminate according to the invention from consists of a foamed synthetic resin layer that is not laminated onto a third layer or only lightly foamed thermoplastic resin layer is laminated.

With regard to the procedural part of the problem, the solution according to the invention is that a foamed synthetic resin web is introduced into a calender, then a web of molten resin coming from a slot nozzle Thermoplastic is fed into the calender and finally a third web into the calender on the side of the web of molten thermoplastic is introduced, which is opposite to the side that carries the foamed synthetic resin sheet, and then the resulting three-layer laminate is passed through a press nip.

It is advisable to equip the calender with chrome-plated rollers.

The three-layer laminate is preferably applied over at least one cooling roll after it has passed through the press nip and guided between take-off rollers and then wound up in a winding station.

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If a laminate is to be produced that contains more than three layers, the first one can be used three-layer laminate must be passed through the machine again as often as required. This is how it is, for example possible to send two three-layer laminates through the calender and with a melted sheet of thermoplastic to glue to make a seven-layer laminate.

The web of the foamed synthetic resin can be produced by blow extrusion, in which a foamable melt is pressed through a nozzle with an annular opening and the resulting tube is inflated from the inside with the aid of a blow line provided in the mandrel of the nozzle . During inflation, the extruded tube can optionally be stretched longitudinally at the same time, for example by passing through the gap between peel rolls which run at a speed greater than the linear speed at which the tube emerges from the nozzle of the extruder. The flattened tube formed in this way can then be cut open and trimmed to give a web of the desired dimensions.

The expansion of the extrudate coming out of the nozzle can be carried out, for example, by means of one of the following methods can be made:

(a) By direct extruder gassing, in which the polymeric resin is passed through a specially designed extruder

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goes, in which the product gels and a volatile blowing agent under high pressure in the gelled material injected and is intensively homogenized in this. The resulting polymer mixture with the Blowing agent is fed to a downstream cooling extruder or possibly in a suitable one Way extended single or twin screw main extruder cooled and then essentially as a hose extruded in the manner described above. (b) An alternative is a polymeric synthetic resin how to produce polystyrene, in which a blowing agent is contained, which under the extrusion conditions volatilized or activated. In this case, the foamable particles are through a conventional extruder and run as an inflated tube in the one described above Way extruded.

The rolls made of foamed synthetic resin produced in this way are then, preferably after elapse of Hours to normalize the foam, set to the version of the calender.

The extruder, which uses a slot die to produce a web of molten thermoplastic, is also used for feeding this path is used to the roller assembly and in particular to the center of a set of four rollers. At the same time, the roll with the web of foamed synthetic resin is a guide roll and from there the press roll

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Gap fed, which is located between the second and third roller. A laminate is then created by pressing the two layers together.

A third web is then fed from below the second roller on the opposite side of the layer of molten all-thermoplastic that is being extruded, and this third layer is then bonded directly to the all-thermoplastic while it is being pressed. The resulting three-layer laminate made of foam, solid material and another material, for example paper, textile or thermoplastic, can then be diverted via a third cooling roller and passed via a fourth chrome guide roller to two rubber peeling rollers and from there to a winding station.

The laminate produced in this way therefore uses the solid extrudate both as an adhesive layer and as a stiffening agent. It also offers better impact resistance than one directly with an adhesive (e.g. Gununilatex) Glued laminate made of foam and, for example, paper or textile. An additional advantage of the laminate, where the all-thermoplastic is used as the adhesive, its ability to withstand the load over the distribute all of the solids, giving the foam greater compressive strength than otherwise would be the case.

The materials that are particularly suitable for the production of the foamed synthetic resin include poly-

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more aromatic vinyl compounds, for example polystyrene, as well as copolymeric aromatic vinyl compounds. A tough polystyrene, for example polybutadiene polystyrene or acrylonitrile, butadiene styrene / polystyrene and / or Styrene butadiene rubber / polystyrene can also be used. Furthermore, for example, foam polyethylene, polypropylene or polyvinyl chloride can be used. In addition, appropriate flame retardants can be added to the extrudate be added, either in the foam body or in the solid material, in order to produce a flame-retardant laminate.

The solid adhesive layer is preferably made of synthetic resins that are the same or similar to them which the foamed layer consists. The full layer is of course not made of foamed materials, although for certain applications it can be expanded slightly to accommodate densities as low as 720 kg / m (45 lb / ft) demonstrate. Foamed polystyrene, for example, can be made with full ABS or foam polyethylene with full polypropylene be layered. Furthermore, the softening point of the foam is preferably close to (for example 10 C) that of the solid material that is extruded to make a good laminate.

In a particular embodiment of the invention a non-woven textile is used, for example nylon with a very low mass, for example

2
show 70 g / m 2 for the surface of a laminate

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To form solid and expanded polystyrene, so that a very economical finished product is created .

The laminates according to the invention have many uses, such as in the interior trim of vehicles, boats, furniture and the like, and because of the possibility of using a laminate roller in a thermoforming process, fully molded parts can be produced very quickly and cheaply.

While the density of the foamed material is not critical, it is preferably no more than 480 kg / m ³ (30 lb / ft ³ ).

As already mentioned above , the third layer of the laminate can be, for example, a woven or non-woven textile or a synthetic resin or paper which is able to adhere to the full layer of synthetic resin or paper and which can be printed or embossed can. This third layer preferably has a weight of 50 to 400 g / m 2. If the third layer consists of a thermoplastic, this may have been embossed, for example, before or during the layering process, provided that, in the case of a thermoplastic, the embossing has been carried out with a pre-embossed material at a temperature higher than that of the molten material thermoplastic adhesive layer is.

Of course, if the third layer is made of a thermoplastic, the laminate can be thermoformed . A great advantage of the laminates according to the invention lies

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but in that even if the third layer is made, for example, of a non-woven textile is, thermoforming is still possible.

A particularly preferred three-layer laminate according to the invention is characterized by, for example a layer of particularly tough polystyrene foam or crystal polystyrene foam with a density of no less

3 3

than 32 kg / m and not more than 480 kg / m, which is layered together with a fully adhesive layer of particularly tough polystyrene, which has a thickness of not less than 0.075 mm and not more than 1.25 mm and a density of 720 kg / m up to 1040 kg / m and is in turn layered together with a third layer, the surface layer, made of a non-woven nylon fabric, which is a weight

2 2

of not less than 50 g / m and not more than 150 g / m

A preferred method of trimming shapes made from laminates according to the invention is to use an electrically heated steel knife. This steel knife is connected to a transformer and profiled so that it corresponds to the shape of the required cutting line. If the molding requires a continuous trimming edge, the two ends of the knife are electrically insulated from one another by means of a thermally conductive material. The preferred method is to use a line transformer to drop the voltage from 415 volts to 12 volts

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to be used with a single-phase output with a power range of 0-300 A. This is used together with a double-wound transformer and a voltmeter to provide precise voltage control of the electrical current at the knife and consequently for precise temperature control . The blade temperature should range from 160 to 220 ⁰ C, but preferably in the range of 170 to 180 ° C.

A second unit can be used to cut sections, for example fastening holes or the like, from the molding , if such are required .

The entire trimming system is expediently attached to a compressed air cylinder with an actuating device in order to provide the pressure on the cutting knife required for trimming.

This trimming method is preferably used in the case of surfaces made of non-woven textile.

The following examples are intended to illustrate the invention.

example 1

A 4.5 "/ 6" -Gloucester engineering tandem foam extrusion system was charged with a batch of 30 wt .-% Carinex- SI.78 polystyrene and 70 wt .-% Carinex HR polystyrene, in the above 0 , 1 % by weight of finely divided talc as a nucleating agent was mixed in with 0.05% by weight of risella oil (white oil) as a dispersing agent. The mixture was then

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at a melting temperature of 170 ⁰ C and injected a mixture of 80% Arcton 11 and 20% Arcton 12 fluorocarbon into the cylinder at the point of decompression on the screw. The resulting mixture was then compressed again and pumped into the 6 "cooling extruder and extruded through an annular nozzle with a melt temperature of about 110 ° C. and an output of 220 kg / h. The resulting tube was then stretched and inflated, in the ratio of 3.5: \ to produce two flat sheets with a width of 1080 mm and a density of 96 kg / m. These sheets were then wound up.

After a ripening time of 24 hours, one of the rolls was taken to a layering line and placed in one Unwind stand set over a three-roll calender. A mixture of 30% by weight Carinex-HR and 70% by weight Carinex-SI 78-polystyrene was then replaced by a conventional one Gloucester 4-1 / 2 "extruder with a melting temperature of 180 C and then extruded through a slot nozzle, to produce a web with a thickness of 0.25 mm at an output of 300 kg / h. The linear speed was about 18 m / min.

A roll of nonwoven nylon fabric weighing 70 g / m 2 was then pulled off a second unwind stand to the second roll of the calender and into the press nip, which has a gap width of 0.5 mm

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a roller pressure of 5.6 kgf / cm. This non-woven fabric was brought up to the side of the full layer, the

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facing away from the foam inlet. The roller temperature of the second roller was 60 C.

The resulting laminate was passed over a third cooling roller at a temperature of 40 ° C. and through the rubber take-off rollers to the winding station. The roll of material produced in this way was transferred to a heat forming unit with endless roll feed, passed through a heating sequence station (heaters on two sides) and then thermoformed in a matched metal form . The molded parts were then trimmed for stacking and use.

Example 2

A roll of expanded polystyrene foam made by the method described above was brought to the lay-up line and placed in the unwind stand over a three-roll lay-up calender. The extrusion conditions were set up on a Gloucester 4-1 / 2 "-32: 1-LD extruder in such a way that a melting temperature of 180 C. These temperature conditions were as follows: batch inlet 152 C; melting zone 170 Ci, compression zone 200 C; dosing zones 1, 2 and 3 200 ⁰ C; sieve 200 ° C; slide units 200 ° C and 200 ° C; adapter 200 ⁰ C; nozzle body 208 ° C, 206 ⁰ C, 202 ⁰ C, 202 ⁰ C and 208 ⁰ C.

A mixture of 60% Shell-Carinex HR and 40% Carinex TGH was fed into the machine , the screw filled and the material with a screw speed of 50 rpm

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processed. A solid polystyrene sheet having a thickness of 0.150 mm was extruded to the roll calender, and the above-mentioned sheet of expanded polystyrene was also passed through the nip. A gap width of 0.25 mm was used. The roller pressure on

2
Gap was 5.95 kgf / cm. The roller temperature setting

was 55 ° C for the press roll and 35 ° C for the chill roll.

A roll of non-woven, point-bonded PBS.3-

2 Material with a weight of 150 g / m, which consisted of a nylon polymer of the ICI Cambrelle fabric range, was fed into the nip and the entire laminate was brought together and processed at a speed of 18 m / min so that a Output of 200 kg / h resulted.

Example 3

In a manner which corresponds to that described in Example 1, a roll of a foamed polystyrene sheet was placed again in the layering system and the temperatures mentioned in Example 2 were set again on the extruder .

After a gap width of 0.125 mm on the calender

2
a roller pressure of 5.6 kp / cm, roller temperatures of

65 ° C. on the press roll and 40 ° C. on the cooling roll were set, a feed of 70% Shell Carinex HR and 30% Shell Carinex TGH was sent through the extruder.

In this case, an extrudate was formed with a thickness of 0.2 mm, and a roll of sheet-bound gray staple fibers with a weight was placed in the nip

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of 85 g / m from the ICI Cambrelle series.

The result was a laminate consisting of foamed polystyrene, solid polystyrene and an ABS-85 sheet of Cambrelle quality. A throughput speed of 15 m / min provided an output of 210 kg / h.

Example 4

A roll of web material made of foamed polystyrene, which was prepared according to the method described above, was placed in the unwind stand of a layering system. The web was fed into a press nip which was 0.5 mm wide with a roller pressure

2
of 5.9 5 kgf / cm. The temperature of the press roll was

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60 C, that of the chill roll 40 C. A charge of 70% Dow Styron 686 and 30% Dow Styron 461 was fed into the layer extruder and used to produce a full laminate with a thickness of 0.2 mm at a line speed of 18 m / min . The temperature settings for this batch were: Screw inlet 155 C, the melting zone 174 ° C, compression zone 197 ° C, metering zones 204 ° C, 210 ° C and 210 ⁰ C, sieve 200 ° C, slider 1 of 200 ° C, slide 2 200 ° C , Adapter 205 ⁰ C, nozzle 210 ° C, 204 ° C, 200 ° C, 200 ° C and 204 ° C. A screw speed of 55 rpm was used

The surface coating material that was used was again selected from the I.C.I. Cambrelle series. In In this case, however, a sheet-bound staple fiber was used

(Code ABS 265) introduced with a weight of 265 g / m.

The laminate combination of expanded polystyrene sheet, Solid and ABS.265 surface or. Top layer was

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then withdrawn and wound in a conventional manner after passing through the peel rolls. In the This way produced web could be used as a carpet covering for gear box cladding in vehicles, boat linings and the like can be used.

Example 5

A prepared laminate of point-bonded non-woven fiber PBS, 3 was placed in the unwind stand a stratification system set. This laminate already consisted of the top layer, the fully adhesive layer and a foam backing. The material was in the The nip of the layering roll was introduced, which was 0.25 mm

2 and a roller pressure of 5.6 kgf / cm was set. A full film was made from the layering machine extruded when operating under the same conditions as in Example 4 above using of the same enema, i.e. Dow Styron 686 70% and Dow Styron 461 30%. This latter mixture produced a medium-impact, reasonably flexible Foil with the adhesive layer of the laminate as solid material.

In this case it was essential to ensure that the foam layer was in contact with the extruding one Layer of full polystyrene adhesive arrives. At the same time, a layer of stretchable or extendable creped was applied and bleached Kraft paper weighing 50 g / m 2 from the other side of the stacker and passed into the press nip. This created a five-

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Layered laminate consisting of the original PBS.3 material together with a fully adhesive layer, a foam core, a second fully adhesive layer and a layer of crepe paper.

The addition of the crepe helps to achieve better impact resistance and can also be used to create a good surface for adhesive application to finished moldings, such as automobile roof panels, which must be adhered to the metal shell into which they are inserted.

Example 6

A laminate made from ABS-85-I .CI.

Staple fiber in surface binding weighing

2
8 5 g / m 2 was placed in the unwind stand of the laminating line, ensuring that the material enters the press roll so that the sheet of foamed polystyrene is in a position in which it comes into direct contact with the solid extrudate . A batch material of 50% Dow Styron 686 and 50% Dow Styron was fed to the extruder to make a medium / high impact laminate, and a solid sheet 0.150 mm thick was extruded under the same conditions as above Example 4 have been given. A throughput speed of 18 m / min was used, and with the entry of the prepared laminate and the fully adhesive layer into the press nip of the calender, a role of plant power was

2 paper with a weight of 400 g / m at the bottom

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the full adhesive layer introduced. The whole was layered together, to produce a five-layer laminate which from the ABS.85 staple fiber together with a 0.2 now thick solid material layer, a foam core having a means

2
Weight of 200g / m, a 0.150 mm thick layer of impact-resistant adhesive polystyrene and a final sub-layer of vegetable kraft paper.

The laminate produced in this way has excellent impact resistance and can be used to produce trimmed panels for the interiors of automobiles, caravans and the like. The product produced in this way can assume small radii and can be easily shaped, but should not be used for deep-drawing work because Kraft paper is not easily stretchable. The laminate produced in this manner has a low weight, is very economical to manufacture and has a pleasant aesthetic appearance, while simultaneously having sufficient strength for practical use in automobile parts.

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Claims (15)

Patent claims : 1 . Laminate, characterized in that it consists of a foamed synthetic resin layer which is laminated onto a thermoplastic resin layer which is in turn laminated to a third layer and which is not or only slightly foamed. 2. Laminate according to claim 1, characterized in that the resin of the foamed synthetic resin layer is a polymeric or copolymeric aromatic vinyl compound, polyethylene, polypropylene or polyvinyl chloride. 3. Laminate according to claim 1 or 2, characterized in that the resin of the foamed synthetic resin layer contains a flame retardant additive. 4. Laminate according to one of claims 1 to 3, characterized in that the thermoplastic resin layer is a layer made of a polymeric or copolymeric aromatic vinyl compound, polyethylene, polypropylene or polyvinyl chloride. 5. Laminate according to one of claims 1 to 4, characterized in that the resin of the foamed synthetic resin layer is the same or similar to the resin of the thermoplastic resin layer. 6. Laminate according to one of claims 1 to 5, characterized in that the third layer is a woven or non-woven textile, a synthetic resin or paper . 7. Laminate according to claim 6, characterized in that the third layer is printed or provided with embossments is. 709848/0841 ORIGINAL INSPECTED ^Ä 272ΠΒ16 8. Laminate according to claim 6 or 7, characterized in that the third layer has a weight of 50 to 400 g / m ² . 9. Laminate according to one of claims 1 to 8, characterized in that the foamed synthetic resin layer is a Has a density of not more than 480 kg / m. 10. Laminate, characterized by a layer made of particularly tough polystyrene foam or crystal polystyrene foam with a density of not less than 32 kg / m and not more than 480 kg / m, which are layered together with a fully adhesive layer made of particularly tough polystyrene which has a thickness of not less than 0.075 mm and not more than 1.25 mm and a density of 720 kg / m to 1040 kg / m and in turn with a third layer, the surface layer, from one not woven nylon fabric is layered together, weighing not less than 50 g / m ~ and not more than 150 g / m Has. 11. Method of manufacturing the laminate according to Claims 1 to 10, characterized in that one foamed synthetic resin web is introduced into a calender, then a web coming from a slot nozzle is made molten thermoplastic is fed into the calender and finally a third web into the calender on the side of the web of molten thermoplastic is introduced, which is opposite to the side that carries the foamed synthetic resin sheet, and then the resulting three-layer laminate through a press nip is passed through. 7098AR / 08A1 - ve - 12. The method according to claim 11, characterized in that the calender is equipped with chrome-plated rollers . 13. The method according to claim 11 or 12, characterized in that the three- layer laminate is passed over at least one cooling roller after passing through the press nip. 14. The method according to any one of claims 11 to 13, characterized in that the three- layer laminate is passed at least one more time through the calender in order to produce a laminate which contains more than three layers. 15. The method according to any one of claims 11 to 13, characterized in that two three- layer laminates are passed through the calender and bonded to a molten all-thermoplastic in such a way that a seven -layer laminate is formed.